THE ULTIMATE OPTICAL LAY-UP STATION

R

REDEFINING ACCURACY

THE ULTIMATE OPTICAL LAY-UP STATION

DIRECT OPTICAL REGISTRATION

WORK IS EASY WHEN YOU HAVE ALL THE RIGHT TOOLS AROUND YOU!

Duetto Integrated Systems, Inc. was founded with the goal of designing and building automated systems that are more accurate. With decades of extensive experience designing and building PC board registration machines, we created a family of industry leading machines with unparalleled efficiency.

Since its founding in 1999 DIS’s business has been multilayer registration. Through the years we have developed and refined the process, the methods and the equipment set to achieve the highest possible level of registration with the materials that are in use today. Our specialty is in providing applications and the process recommendations in registration. When installing a system our team of engineers not only trains our customers on the systems usage, but also guides our customers in every step of the process from imaging to lamination and inspection of every aspect of registration.

Fueled by innovation, we aim to redeFine the standard For multi-layer registration equipment by continually innovating and providing our unique applications support.

ABOUT US

1999DIS is Incorporated

2002The first DOR System is Delivered

2006SmartWeld System Introduced

2008Pin Welding System Introduced

2010Granted Patents in Taiwan

2012Barcode Panel

Traceability Introduced

2014Granted Patent for Multi-Camera

Measurement System

2006DIS enters Asia Market

2007Array Lighting Scheme Introduced

2008Manual Flex System Introduced

2011Granted U.S. & Worldwide Patents for Direct Optical Registration

2013Automated Flex & Rigid Flex Systems Introduced

TIMELINE

2016Shipped 100th System

2019Remote Set-up Wizard

Implemented

DIRECT OPTICAL REGISTRATION™

Direct Optical Registration™ is the cornerstone of DIS Inc. We developed this technology after seeing the shortcomings of manual lay-up pin lamination. Using Direct Optical Registration™ eliminates the handling tolerances, increasing the accuracy of layer-to-layer registration. Without the fixed tooling set-ups, a wider range of panel sizes can be processed.

Keeping efficiency as a key focus to a machine’s workflow, we have kept our process simple. In our PRS and RFS machine families, when a job is set up, cameras are moved to a set dimension where they are locked in for the remainder of a job. This creates a set of reference points to which the targets are aligned, rather than measuring to the previous innerlayer’s targets, eliminating an extra variable. Once an innerlayer has been positioned, it is then clamped down in place and won’t be released until after the welding cycle.

Our Direct Optical Registration™ has only just begun to see its full capabilities. In our CMS machine and Multi-Camera preload systems, up to 10 cameras simultaneously measure targets, spread, innerlayer shape and front to back registration. This measurement data determines the best fit for each layer before entering alignment. With new developments in the works, we are constantly searching for more applications of Direct Optical Registration™.

+/- 17 µm alignment tolerance or better

Cameras stay fixed once job dimensions are set

Easily align thin cores (1mil-25 µm)

Layers are aligned to fixed reference point

Cameras

Layer 2/3

Layer 4/5

Layer 6/7

Layer 8/9

CAPABILITIES

With an increasing range of panel thicknesses and materials entering the marketplace, having a machine with a wide range of processing capabilities is critical. The two figures below are DIS customer provided production panel cross sections of a 44-layer stack up (Figure 1) and a 34-layer stack up of mixed materials of different thickness and sub-laminated panels (Figure 2). The accompanying chart is a line graph of the Long Axis of the stack-up from Figure 1

Figure 2Figure 1

Repeatable alignment

Discover lamination trends

Easily transition between stack heights

-5

-4

-3

-2

-1

0

1

2

3

4

5

2 4 6 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44

Acc

urac

y, m

ils

Long Axis After Lamination

Panel 1 Panel 2 Panel 3 Panel 4

SmartWeld™ is another industry leading innovation of DIS Inc. Our Patented Variable Coupled Inductive welding system allows rapid and precise heat control throughout a welding cycle. The entire cycle is programmable, allowing the process engineer control of the Ramp Rate, Hold Time and Cooling. The engineer can save a series of these weld profiles for faster referencing when choosing the next job.

Each set of weld heads has a temperature feedback pad inside of an aluminum body allowing more accurate, and safe, use of temperature throughout weld cycle. The aluminum body is cool running, creating a more efficient weld. SmartWeld™ increases productivity by providing repeatable and predictable welds, cycle after cycle.

SMARTWELD™ TECHNOLOGY

The complete weld cycle is controlled similar to a lamination press cycle. The different parameters are set, such as maximum temperature, temperature ramp rate, hold (soak) time, cooling time and pressure. Each weld station is independently controlled for maximum flexibility.

Welding Process

- ramp rate

- weld hold time

- cooling

Electrically coupled induction heads

Contained electromagnetic fields

Aluminum body design

0

20

40

60

80

100

120

140

160

1 10 24 29 32

TEM

PERA

TURE

(C)

TIME (sec)

WELD CYCLE

Welding Process

X-ray MeasureMents

pre-lamination post-lamination

PROCESS BENEFITSPanels can be measured after welding using an X-ray machine, this allows the process engineer to check the registration prior to the lamination cycle. This is not possible with any pin system.

After the lamination cycle, panels can be measured again. This allows the process engineer to check the registration and compare with the pre-lamination data, now it is possible to adjust the lamination cycle using real data.

Eliminate distortion of innerlayers at lamination pin locations

Tooling Slot

Layer distortion / Tear

eliMinate distortion oF innerlayers at laMination Pin locations

multiple machine conFigurations to best suit production volumes

capable oF handling multiple stack-ups

modular upgrades available For pre and post alignment stations

PRS Shuttle with WPS

104” x 120” x 65”

264cm x 305cm x 165cm

13” x 14” to 24” x 30”

330mm x 355mm to 610mm x 762mm

FOOTPRINT

PANEL SIZE

use set-up wizard to remotely program and edit job set-ups For Faster throughput

PRSRIGID

PIN-LESS REGISTRATION SYSTEM

PRS-STD

48” x 43” x 65”

122cm x 109cm x 165cm

12” x 14” to 24” x 30”


FOOTPRINTPANEL SIZE

PRS L/U

16” x 14” to 24” x 30”


32” x 99” x 65”

81cm x 252cm x 165cm

PANEL SIZE FOOTPRINT

WPS - Modular Stacker Unit

45” x 42” x 69”

115cm x 106cm x 176cm

12” x 14” to 24” x 30”


FOOTPRINTPANEL SIZE

PRS L/U Extended

32” x 131” x 65”


16” x 14” to 24” x 36”


FOOTPRINTPANEL SIZE

32” x 99” x 65”


12” x 14” to 22” x 28”


FOOTPRINTPANEL SIZE

Capable of unique larger panels ADDITIONAL INFORMATION

Automatic Unloading Feature with pass through designOptional Offload Stacker Capability

ADDITIONAL INFORMATION

Advanced unloading feature capable of processing smaller panel sizesADDITIONAL INFORMATION

Modular Stacker Unit for PRS L/U, and PRS SH models. Removable trolley


PRS L/U Advanced

RIGID

CMSCAMERA MEASUREMENT SYSTEM

13” x 14” to 24” x 30”


48” x 43” x 65”

121.9cm x 109.2cm x 165.1cm

PANEL SIZE

FOOTPRINT

display predictive modeling oF the lay-up and a virtual build oF the panel aFter lay-up

cameras can be moved to image area For more accurate measurement

multiple positioning algorithms can be chosen based on panel characteristics

prs l/u system with intergrated multi-camera preload station

Multi-caMera Preload station

Multi-caMera Preload station

MFSMANUAL FLEX SYSTEM

This system will process all panel sizes

40” x 41” x 61”

101.6cm x 104.2cm x 155cm

PANEL SIZE

FOOTPRINT

unlimited bonding locations

available with dual independent heads

multiple head set-ups• smartweld™ heads

• hot heads

• combination oF both (available on dual head systems)

RIGID-FLEX

RFS

13” x 14” to 24”x 30”


90” x 54” x 72”

229cm x 137cm x 183cm

PANEL SIZE

FOOTPRINT

RIGID-FLEX SYSTEM

RIGID-FLEX

optically align and bond rigid, Flex and rigid-Flex boards

allows For insertion oF Fillers

automatically aligns layers and pre-preg

use set-up wizard to remotely program and edit job set-ups For Faster throughput

RFB

12” x 14” to 24” x 30”


90” x 54” x 72”

229cm x 137cm x 183cm

PANEL SIZE

FOOTPRINT

8 movable bonding heads, 4 top and 4 bottom

RIGID-FLEX BONDER

multiple head set-ups

• smartweld™ heads

• hot heads

gerber data used to determine bond postions

internal and perimeter bonding positions

PWSPIN

PIN WELDING SYSTEM

alignment pins are centerline locations

(as speciFied by customer)

smartweld™ technology

simple touch screen controls

cross bar

10” x 12” to 24” x 28”

255cm x 305mm to 610mm x 710mm

PLC based controls

PANEL SIZE


PWS 100

66” x 40” x 48”

102cm X 264cm X 122cm

FOOTPRINT

10” x 12” to 24” x 28”


PC based touch screen controls

Dual weld stations for increased throughput

Designed for ergonomic throughput in a high volume PCB shop

PANEL SIZE


PWS Shuttle

104” x 40” x 63”

264cm x 102cm x 159cm

FOOTPRINT

10” x 12” to 24” x 28”


40” X 104” X 63”

102cm X 264cm X 160cm

PANEL SIZE

FOOTPRINT

PWS 500


PC based touch screen controls

Stores Set-ups and Historical Data

DIS offers Punch & Die Block sharpening services. All punch and die block sets are evaluated for damages and missing parts. The punches and dies are removed from the blocks to be inspected determining if they can be reinstalled or need to be replaced. Punches that are sharpened are ground down and set to the correct length.

This service is also provided on most punching machines that have not been upgraded by DIS, Inc.

sharpening – punch & die blocks:

VISION POSITIONING RETROFIT

Seeing the growing share of outdated post-etch punches, DIS Inc. is using their years of experience to upgrade these OPE and Semi-OPE machines.

Each machine is evaluated by DIS Inc. ensuring that the punches, dies and castings (rails) are in good working order.

If the machine qualifies for upgrading, DIS Inc. begins manufacturing and completing many of the assemblies before the machine is delivered to us to decrease turnaround time.

Once at our facility the machine goes through an extensive rebuild.

The positioning and vision systems are removed along with all wiring and associated plumbing, replacing it with DIS Inc’s XYY Positioners, eliminating the backlash associated with lead screws and are self cleaning.

POST-ETCH PUNCH

VPR

ATP & OPE 3000 series systems may also be upgraded and converted to standard OPE.

AAP artwork punches semi or automatic may also be upgraded to automatic punches

Proprietary DIS, Windows based, software with Data Logging and Ethernet connectivity

Automatic target acquisition eliminating the need for operator assistance.

New XYY positioning mechanism

Improved target recognition

New Digital Cameras

Optional conversion of two top cameras to colinear cameras, 2 top and 2 bottom

New Electrical and Control Package

New Touchscreen monitor

Elimination of halogen bulb light box with integral LED lighting.

Bulky stand alone console eliminated

All safety features are upgraded to the current safety standards including keyed magnetic interlock switches and a

finger safe light curtain.

All upgrades listed in Standard OPE Upgrade additionally:

The positioning system manipulates the layer/artwork, converting a Semi machine into an Automatic machine.

standard ope upgrade semi ope upgrade

Min - 25mmMax - 100mm

10 mm

10 mm

With the barcode scanner, operators can scan an entire stack-up into the computer to set alignment tolerances and weld profiles. This information can then be pre-loaded into a machine, saving time and ensuring that the layers are placed in the correct order during lay-up, creating a mistake proof process.

Available on: CMS, RFS, and PRSAvailable on: CMS, RFS, and PRS

TARGET

ACCESSORIES

BARCODE SCANNERS

Hand-Held scanner

Machine-Mounted Scanner

THICKNESS GAUGEThe Thickness Measurement option allows the engineer to enter layer and prepreg thickness in the job set-up along with tolerances. This feature minimizes the possibility of loading too many or too few prepregs.

Available on: All PRS-L/U & PRS-SH MachinesAvailable on: All PRS-L/U & PRS-SH Machines

MACHINE

BARCODE

SPRING LOADED CORNER BLOCKS

BLOCKING PLATES

PANEL FLIPPER

Corner Blocks allow for easy adjustment of multiple panel sizes. Using the blocks to hold the completed book eliminates the need for pins that could potentially damage the lamination press platens.

Blocking Plates provide a lighter alternative to lamination plates with pins. No height calculations are needed. Each size specific set provides security for the panel during transportation between lay-up and lamination.

The Panel Flipper is an essential tool to ensure the safe handling of welded panels prior to the lamination cycle. By evenly clamping welded panels together, operators can handle them without the risk of disrupting alignment when removing backer boards and completing the build by adding outer layer foils, separator plates and other build elements.

ACCESSORIESLAMINATION

REDEFINING ACCURACY

CONTACT

ADDRESS

DIS INC. 85 HOFFMAN LANE, SUITE QISLANDIA, NY 11749USA

PHONE & FAX

Phone: + 1 (631) 851-0102 Fax: + 1 (631) 967-1540

ONLINE

EMAIL : [email protected] URL: WWW.DISTECHNOLOGY.COM

Thank YouDIS, Inc. would like to thank you for your interest in our systems. We’ve placed years of careful research and development into each of our systems to bring you the highest quality products on the market. DIS, Inc. is here to work with you to ensure that each product purchased completely fulfills its need. On behalf of the entire DIS, Inc. team, we look forward to working with you.

Sincerely,

Anthony FaraciAnthony FaraciFounder & President

The Information in this publication in based on DIS Inc.’s internal research/evalution at the time of release and is subject to change

without notice. Company and product names mentioned in the catalog are either trademarks or registered trademarks.

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THE ULTIMATE OPTICAL LAY-UP STATION